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Chapter 15
15-1

Given: Uncrowned, through-hardened 300 Brinell core and case, Grade 1, NC = 109 rev of
pinion at R = 0.999, N P = 20 teeth, NG = 60 teeth, Q v = 6, Pd = 6 teeth/in, shaft angle
90, n p = 900 rev/min, J P = 0.249 and JG = 0.216 (Fig. 15-7), F = 1.25 in, S F =
S H = 1, K o = 1.
d P = 20/6 = 3.333 in

Mesh

dG = 60/6 = 10.000 in
Eq. (15-7):

vt = (3.333)(900/12) = 785.3 ft/min

Eq. (15-6):

B = 0.25(12 6) 2/3 = 0.8255

A = 50 + 56(1 0.8255) = 59.77


0.8255

59.77 + 785.3
= 1.374
Kv =
59.77

Eq. (15-5):
Eq. (15-8):

vt, max = [59.77 + (6 3)]2 = 3940 ft/min

Since 785.3 < 3904, K v = 1.374 is valid. The size factor for bending is:
K s = 0.4867 + 0.2132/6 = 0.5222

Eq. (15-10):

For one gear straddle-mounted, the load-distribution factor is:

K m = 1.10 + 0.0036(1.25) 2 = 1.106

Eq. (15-11):
Eq. (15-15):

(K L ) P = 1.6831(109 ) 0.0323 = 0.862

(K L ) G = 1.6831(109 /3) 0.0323 = 0.893

Eq. (15-14):

(C L ) P = 3.4822(109 ) 0.0602 = 1
(C L ) G = 3.4822(109 /3) 0.0602 = 1.069
K R = 0.50 0.25 log(1 0.999) = 1.25


C R = K R = 1.25 = 1.118

Eq. (15-19):

(or Table 15-3)

Bending
Fig. 15-13:
Eq. (15-4):
Eq. (15-3):

0.99 St

= sat = 44(300) + 2100 = 15 300 psi

(all ) P = swt =
W Pt =
=
H1 =

Eq. (15-4):

(all ) G =

sat K L
15 300(0.862)
=
= 10 551 psi
SF K T K R
1(1)(1.25)

(all ) P F K x J P
Pd K o K v K s K m
10 551(1.25)(1)(0.249)
= 690 lbf
6(1)(1.374)(0.5222)(1.106)
690(785.3)
= 16.4 hp
33 000
15 300(0.893)
= 10 930 psi
1(1)(1.25)

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WGt =

10 930(1.25)(1)(0.216)
= 620 lbf
6(1)(1.374)(0.5222)(1.106)

620(785.3)
= 14.8 hp Ans.
33 000
The gear controls the bending rating.
H2 =

15-2

Refer to Prob. 15-1 for the gearset specifications.

Wear
sac = 341(300) + 23 620 = 125 920 psi
Fig. 15-12:
For the pinion, C H = 1. From Prob. 15-1, C R = 1.118. Thus, from Eq. (15-2):
(c, all ) P =

sac (C L ) P C H
SH K T C R

(c, all ) P =

125 920(1)(1)
= 112 630 psi
1(1)(1.118)

For the gear, from Eq. (15-16),

B1 = 0.008 98(300/300) 0.008 29 = 0.000 69
C H = 1 + 0.000 69(3 1) = 1.001 38
And Prob. 15-1, (C L ) G = 1.0685. Equation (15-2) thus gives
(c, all ) G =

sac (C L ) G C H
SH K T C R

125 920(1.0685)(1.001 38)

= 120 511 psi
1(1)(1.118)

= 2290 psi
= 0.125(1.25) + 0.4375 = 0.593 75
= 0.083
=2


Fd P I
(c, all ) P 2
=
Cp
K o K v K m Cs C xc
 


1.25(3.333)(0.083)
112 630 2
=
2290
1(1.374)(1.106)(0.5937)(2)

(c, all ) G =
For steel:
Eq. (15-9):
Fig. 15-6:
Eq. (15-12):

Cp
Cs
I
C xc

Eq. (15-1):

W Pt

= 464 lbf
464(785.3)
= 11.0 hp
33 000
 


1.25(3.333)(0.083)
120 511 2
t
WG =
2290
1(1.374)(1.106)(0.593 75)(2)
H3 =

= 531 lbf
H4 =

531(785.3)
= 12.6 hp
33 000

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381

Chapter 15

H = 11.0 hp Ans.
The pinion controls wear:
The power rating of the mesh, considering the power ratings found in Prob. 15-1, is
H = min(16.4, 14.8, 11.0, 12.6) = 11.0 hp Ans.
15-3

AGMA 2003-B97 does not fully address cast iron gears, however, approximate comparisons can be useful. This problem is similar to Prob. 15-1, but not identical. We will organize the method. A follow-up could consist of completing Probs. 15-1 and 15-2 with
identical pinions, and cast iron gears.
Given: Uncrowned, straight teeth, Pd = 6 teeth/in, N P = 30 teeth, NG = 60 teeth, ASTM

30 cast iron, material Grade 1, shaft angle 90, F = 1.25, n P = 900 rev/min,
n = 20 ,
one gear straddle-mounted, K o = 1, J P = 0.268, JG = 0.228, S F = 2, S H = 2.
Mesh

d P = 30/6 = 5.000 in
dG = 60/6 = 10.000 in
vt = (5)(900/12) = 1178 ft/min

Set N L = 107 cycles for the pinion. For R = 0.99,

Table 15-7:

sat = 4500 psi

Table 15-5:

sac = 50 000 psi

Eq. (15-4):

swt =

sat K L
4500(1)
=
= 2250 psi
SF K T K R
2(1)(1)

The velocity factor K v represents stress augmentation due to mislocation of tooth profiles
along the pitch surface and the resulting falling of teeth into engagement. Equation
(5-67)
shows that the induced bending moment in a cantilever (tooth) varies directly with E of the
tooth material. If only the material varies (cast iron vs. steel) in the same geometry, I is the
same. From the Lewis equation of Section 14-1,
=

Kv W t P
M
=
I /c
FY

We expect the ratio CI /steel to be

CI
(K v ) CI
=
=
steel
(K v ) steel


E CI
E steel

In the case of ASTM class 30, from Table A-24(a)

( E CI ) av = (13 + 16.2)/2 = 14.7 kpsi
Then

(K v ) CI =

14.7
(K v ) steel = 0.7(K v ) steel
30

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Our modeling is rough, but it convinces us that (K v ) CI < (K v ) steel , but we are not sure of
the value of (K v ) CI . We will use K v for steel as a basis for a conservative rating.
Eq. (15-6):

Eq. (15-5):
Pinion bending

B = 0.25(12 6) 2/3 = 0.8255

A = 50 + 56(1 0.8255) = 59.77


0.8255

59.77 + 1178
= 1.454
Kv =
59.77
(all ) P = swt = 2250 psi

From Prob. 15-1,

K x = 1,

Eq. (15-3):

W Pt =
=
H1 =

K m = 1.106, K s = 0.5222

(all ) P F K x J P
Pd K o K v K s K m
2250(1.25)(1)(0.268)
= 149.6 lbf
6(1)(1.454)(0.5222)(1.106)
149.6(1178)
= 5.34 hp
33 000

Gear bending
WGt

H2 =

JG
W Pt
JP

0.228
= 149.6
0.268


= 127.3 lbf

127.3(1178)
= 4.54 hp
33 000

The gear controls in bending fatigue.

H = 4.54 hp Ans.
15-4

Continuing Prob. 15-3,

Table 15-5:

Eq. (15-1):

sac = 50 000 psi

50 000
= 35 355 psi
swt = c, all =
2


Fd P I
c, all 2
t
W =
Cp
K o K v K m Cs C xc

Fig. 15-6:

I = 0.86

Eq. (15-9)

Cs = 0.125(1.25) + 0.4375 = 0.593 75

Eq. (15-10)

K s = 0.4867 + 0.2132/6 = 0.5222

Eq. (15-11)

K m = 1.10 + 0.0036(1.25) 2 = 1.106

Eq. (15-12)

C xc = 2

From Table 14-8:


C p = 1960 psi

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Chapter 15


Thus,

W =
t

35 355
1960

2 

383


1.25(5.000)(0.086)
= 91.6 lbf
1(1.454)(1.106)(0.59375)(2)

91.6(1178)
= 3.27 hp Ans.
33 000
Rating Based on results of Probs. 15-3 and 15-4,
H = min(5.34, 4.54, 3.27, 3.27) = 3.27 hp Ans.
The mesh is weakest in wear fatigue.
H3 = H4 =

15-5

Uncrowned, through-hardened to 180 Brinell (core and case), Grade 1, 109 rev of pinion at
R = 0.999, N P = z 1 = 22 teeth, NG = z 2 =
 24 teeth,
Q v = 5, m et = 4 mm, shaft angle
90, n 1 = 1800 rev/min, S F = 1, S H = S F = 1, J P = Y J 1
= 0.23, JG = Y J 2 =
0.205, F = b = 25 mm, K o = K A = K T = K = 1 and C p = 190 MPa .
Mesh
Eq. (15-7):
Eq. (15-6):

Eq. (15-5):
Eq. (15-10):
Eq. (15-11) with

d P = de1 = mz 1 = 4(22) = 88 mm
dG = m et z 2 = 4(24) = 96 mm
vet = 5.236(105 )(88)(1800) = 8.29 m/s
B = 0.25(12 5) 2/3 = 0.9148
A = 50 + 56(1 0.9148) = 54.77

0.9148

54.77 + 200(8.29)
Kv =
= 1.663
54.77
K s = Yx = 0.4867 + 0.008 339(4) = 0.520
K mb = 1 (both straddle-mounted),
K m = K H = 1 + 5.6(106 )(252 ) = 1.0035

From Fig. 15-8,

Eq. (15-12):
Eq. (15-19):
From Fig. 15-10,
Eq. (15-9):
Wear of Pinion
Fig. 15-12:
Fig. 15-6:
Eq. (15-2):

Eq. (15-1):

(C L ) P = ( Z N T ) P = 3.4822(109 ) 0.0602 = 1.00

(C L ) G = ( Z N T ) G = 3.4822[109 (22/24)]0.0602 = 1.0054
C xc = Z xc = 2 (uncrowned)
K R = Y Z = 0.50 0.25 log (1 0.999) = 1.25


C R = Z Z = Y Z = 1.25 = 1.118
C H = Zw = 1
Z x = 0.004 92(25) + 0.4375 = 0.560
H lim = 2.35H B + 162.89
= 2.35(180) + 162.89 = 585.9 MPa
I = Z I = 0.066
( H lim ) P ( Z N T ) P Z W
( H ) P =
SH K Z Z
585.9(1)(1)
=
= 524.1 MPa
1(1)(1.118)
 2
bde1 Z I
H
t
WP =
Cp
1000K A K v K H Z x Z xc

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The constant 1000 expresses W t in kN

 


25(88)(0.066)
524.1 2
t
= 0.591 kN
WP =
190
1000(1)(1.663)(1.0035)(0.56)(2)
dn W t
(88)1800(0.591)
=
= 4.90 kW
Eq. (13-36): H3 =
60 000
60 000
H lim = 585.9 MPa
Wear of Gear
585.9(1.0054)
( H ) G =
= 526.9 MPa
1(1)(1.118)


526.9
t
t ( H ) G
= 0.594 kN
WG = W P
= 0.591
( H ) P
524.1
(88)1800(0.594)
H4 =
= 4.93 kW
60 000
Thus in wear, the pinion controls the power rating; H = 4.90 kW Ans.
We will rate the gear set after solving Prob. 15-6.
15-6

Refer to Prob. 15-5 for terms not defined below.

Bending of Pinion
(K L ) P = (Y N T ) P = 1.6831(109 ) 0.0323 = 0.862
Eq. (15-15):
(K L ) G = (Y N T ) G = 1.6831[109 (22/24)]0.0323 = 0.864
Fig. 15-13:
Eq. (15-13):

F lim = 0.30H B + 14.48

= 0.30(180) + 14.48 = 68.5 MPa
K x = Y = 1

Y Z = 1.25, vet = 8.29 m/s

From Prob. 15-5:
K A = 1, K v = 1.663, K = 1, Yx = 0.52, K H = 1.0035,
F lim Y N T
68.5(0.862)
=
= 47.2 MPa
( F ) P =
Eq. (5-4):
SF K Y Z
1(1)(1.25)
( F ) P bm et Y Y J 1
W pt =
Eq. (5-3):
1000K A K v Yx K H
47.2(25)(4)(1)(0.23)
=
= 1.25 kN
1000(1)(1.663)(0.52)(1.0035)
(88)1800(1.25)
H1 =
= 10.37 kW
60 000
Bending of Gear
F lim = 68.5 MPa
68.5(0.864)
( F ) G =
= 47.3 MPa
1(1)(1.25)
47.3(25)(4)(1)(0.205)
WGt =
= 1.12 kN
1000(1)(1.663)(0.52)(1.0035)
(88)1800(1.12)
H2 =
= 9.29 kW
60 000

Y J 1 = 0.23

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Chapter 15

Rating of mesh is
Hrating = min(10.37, 9.29, 4.90, 4.93) = 4.90 kW

Ans.

with pinion wear controlling.

15-7
(S F ) P =

(a)


all

= (S F ) G =

(sat K L /K T K R ) P
t
(W Pd K o K v K s K m /F K x J ) P


all

(sat K L /K T K R ) G
t
(W Pd K o K v K s K m /F K x J ) G

All terms cancel except for sat , K L , and J,

(sat ) P (K L ) P J P = (sat ) G (K L ) G JG
From which
(sat ) G =

JP
(sat ) P (K L ) P J P
= (sat ) P m G
(K L ) G JG
JG

Where = 0.0178 or = 0.0323 as appropriate. This equation is the same as

Eq. (14-44). Ans.
(b) In bending

W =
t

In wear

F Kx J
all
S F Pd K o K v K s K m


sac C L CU
SH K T C R


=

11


= Cp

22

F Kx J
sat K L
S F K T K R Pd K o K v K s K m

W t K o K v K m Cs C xc
Fd P I


(1)
11

1/2
22

Squaring and solving for W gives


 2 2 2  
sac C L C H
Fd P I
t
W =
2
SH
K T2 C 2R C 2P 22 K o K v K m Cs C xc 22

(2)

Equating the
 right-hand sides of Eqs. (1) and (2) and canceling terms, and recognizing
that C R = K R and Pd d P = N P ,
we obtain


(sac ) 22 =

Cp
(C L ) 22

2
SH
(sat ) 11 (K L ) 11 K x J11 K T Cs C xc
2
SF
CH
N P Ks I

For equal W t in bending and wear

2
SH
=
SF

So we get

SF
SF

2
=1


Cp
(sac ) G =
(C L ) G C H

(sat ) P (K L ) P J P K x K T Cs C xc
N P I Ks

Ans.

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(c)
(S H ) P = (S H ) G =

c, all
c


=
P

c, all
c


G

Substituting in the right-hand equality gives

[sac C L C H /(C R K T )]G
[sac C L /(C R K T )] P
 = 

 
C p W t K o K v K m Cs C xc /( Fd P I )
C p W t K o K v K m Cs C xc /( Fd P I )
P

Denominators cancel leaving

(sac ) P (C L ) P = (sac ) G (C L ) G C H
Solving for (sac ) P gives,
(C L ) G
CH
(1)
(C L ) P
From Eq. (15-14), (C L ) P = 3.4822N L0.0602 , (C L ) G = 3.4822( N L /m G ) 0.0602 . Thus,
(sac ) P = (sac ) G

(sac ) P = (sac ) G (1/m G ) 0.0602 C H = (sac ) G m 0G.0602 C H

Ans.

This equation is the transpose of Eq. (14-45).

15-8
Pinion
Gear

Core
( H B ) 11
( H B ) 21

Case
( H B ) 12
( H B ) 22

Given ( H B ) 11 = 300 Brinell

(sat ) P = 44(300) + 2100 = 15 300 psi

Eq. (15-23):
From Prob. 15-7,



J P 0.0323
0.249  0.0323
= 15 300
(sat ) G = (sat ) P m G
3
= 17 023 psi
JG
0.216
( H B ) 21 =

17 023 2100
= 339 Brinell
44

Ans.


2290
(sac ) G =
1.0685(1)
( H B ) 22 =

15 300(0.862)(0.249)(1)(0.593 25)(2)
= 141 160 psi
20(0.086)(0.5222)

141 160 23 600

= 345 Brinell
341

Ans.

.
(sac ) P = (sac ) G m 0G.0602 C H = 141 160(30.0602 )(1) = 150 811 psi
( H B ) 12 =

150 811 23 600

= 373 Brinell
341
Pinion
Gear

Care
300
339

Ans.

Case
373
345

Ans.

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Chapter 15

15-9

Pinion core
(sat ) P = 44(300) + 2100 = 15 300 psi
15 300(0.862)
= 10 551 psi
(all ) P =
1(1)(1.25)
10 551(1.25)(0.249)
Wt =
= 689.7 lbf
6(1)(1.374)(0.5222)(1.106)
Gear core
(sat ) G = 44(352) + 2100 = 17 588 psi
17 588(0.893)
= 12 565 psi
(all ) G =
1(1)(1.25)
12 565(1.25)(0.216)
Wt =
= 712.5 lbf
6(1)(1.374)(0.5222)(1.106)
Pinion case
(sac ) P = 341(372) + 23 620 = 150 472 psi
150 472(1)
= 134 590 psi
(c, all ) P =
1(1)(1.118)
 


1.25(3.333)(0.086)
134 590 2
t
= 685.8 lbf
W =
2290
1(1.374)(1.106)(0.593 75)(2)
Gear case
(sac ) G = 341(344) + 23 620 = 140 924 psi
140 924(1.0685)(1)
= 134 685 psi
(c, all ) G =
1(1)(1.118)
 


1.25(3.333)(0.086)
134 685 2
t
= 686.8 lbf
W =
2290
1(1.374)(1.106)(0.593 75)(2)
The rating load would be
t
Wrated
= min(689.7, 712.5, 685.8, 686.8) = 685.8 lbf

which is slightly less than intended.

Pinion core
(sat ) P = 15 300 psi
(all ) P = 10 551
W t = 689.7

(as before)
(as before)
(as before)

Gear core
(sat ) G = 44(339) + 2100 = 17 016 psi
17 016(0.893)
= 12 156 psi
(all ) G =
1(1)(1.25)
12 156(1.25)(0.216)
Wt =
= 689.3 lbf
6(1)(1.374)(0.5222)(1.106)

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Pinion case
(sac ) P = 341(373) + 23 620 = 150 813 psi
150 813(1)
= 134 895 psi
1(1)(1.118)
 


1.25(3.333)(0.086)
134 895 2
t
= 689.0 lbf
W =
2290
1(1.374)(1.106)(0.593 75)(2)

(c, all ) P =

Gear case
(sac ) G = 341(345) + 23 620 = 141 265 psi
141 265(1.0685)(1)
= 135 010 psi
1(1)(1.118)
 


1.25(3.333)(0.086)
135 010 2
t
= 690.1 lbf
W =
2290
1(1.1374)(1.106)(0.593 75)(2)

(c, all ) G =

The equations developed within Prob. 15-7 are effective.

15-10

The catalog rating is 5.2 hp at 1200 rev/min for a straight bevel gearset. Also given:
N P = 20 teeth, NG = 40 teeth, n = 20 , F = 0.71 in, J P = 0.241, JG = 0.201,
Pd = 10 teeth/in, through-hardened to 300 Brinell-General Industrial Service, and
Q v = 5 uncrowned.
Mesh
d P = 20/10 = 2.000 in,
vt =

d P n P
(2)(1200)
=
= 628.3 ft/min
12
12

K o = 1,
Eq. (15-6):

Eq. (15-5):

dG = 40/10 = 4.000 in

S F = 1,

B = 0.25(12 5)

SH = 1
2/3

= 0.9148

A = 50 + 56(1 0.9148) = 54.77

0.9148

54.77 + 628.3
= 1.412
Kv =
54.77

Eq. (15-10):

K s = 0.4867 + 0.2132/10 = 0.508

Eq. (15-11):

K m = 1.25 + 0.0036(0.71) 2 = 1.252

where
Eq. (15-15):

K mb = 1.25
(K L ) P = 1.6831(109 ) 0.0323 = 0.862
(K L ) G = 1.6831(109 /2) 0.0323 = 0.881

Eq. (15-14):

(C L ) P = 3.4822(109 ) 0.0602 = 1.000

(C L ) G = 3.4822(109 /2) 0.0602 = 1.043

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Chapter 15

Analyze for 109 pinion cycles at 0.999 reliability

Eq. (15-19):

Bending
Pinion:
Eq. (15-23):

K R = 0.50 0.25 log(1 0.999) = 1.25



C R = K R = 1.25 = 1.118

(sat ) P = 44(300) + 2100 = 15 300 psi

Eq. (15-4):

(swt ) P =

Eq. (15-3):

Wt =
=
H1 =

15 300(0.862)
= 10 551 psi
1(1)(1.25)
(swt ) P F K x J P
Pd K o K v K s K m
10 551(0.71)(1)(0.241)
= 201 lbf
10(1)(1.412)(0.508)(1.252)
201(628.3)
= 3.8 hp
33 000

Gear:
(sat ) G = 15 300 psi
15 300(0.881)
= 10 783 psi
1(1)(1.25)

Eq. (15-4):

(swt ) G =

Eq. (15-3):

Wt =

10 783(0.71)(1)(0.201)
= 171.4 lbf
10(1)(1.412)(0.508)(1.252)

H2 =

171.4(628.3)
= 3.3 hp
33 000

Wear
Pinion:
(C H ) G = 1,


I = 0.078, C p = 2290 psi, C xc = 2

Cs = 0.125(0.71) + 0.4375 = 0.526 25

Eq. (15-22):

(sac ) P = 341(300) + 23 620 = 125 920 psi

125 920(1)(1)
= 112 630 psi
1(1)(1.118)


Fd P I
(c, all ) P 2
t
W =
Cp
K o K v K m Cs C xc
 


0.71(2.000)(0.078)
112 630 2
=
2290
1(1.412)(1.252)(0.526 25)(2)

(c, all ) P =
Eq. (15-1):

= 144.0 lbf
H3 =

144(628.3)
= 2.7 hp
33 000

389

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Gear:
(sac ) G = 125 920 psi
125 920(1.043)(1)
= 117 473 psi
1(1)(1.118)
 


0.71(2.000)(0.078)
117 473 2
t
= 156.6 lbf
W =
2290
1(1.412)(1.252)(0.526 25)(2)

(c, all ) =

H4 =
Rating:

156.6(628.3)
= 3.0 hp
33 000
H = min(3.8, 3.3, 2.7, 3.0) = 2.7 hp

Pinion wear controls the power rating. While the basis of the catalog rating is unknown,
it is overly optimistic (by a factor of 1.9).
15-11

From Ex. 15-1, the core hardness of both the pinion and gear is 180 Brinell. So ( H B ) 11
and ( H B ) 21 are 180 Brinell and the bending stress numbers are:
(sat ) P = 44(180) + 2100 = 10 020 psi
(sat ) G = 10 020 psi
The contact strength of the gear case, based upon the equation derived in Prob. 15-7, is


2 
SH
Cp
(sat ) P (K L ) P K x J P K T Cs C xc
(sac ) G =
(C L ) G C H S F
N P I Ks
Substituting (sat ) P from above and the values of the remaining terms from Ex. 15-1,



1.52 10 020(1)(1)(0.216)(1)(0.575)(2)
2290
= 114 331 psi
1.32(1) 1.5
25(0.065)(0.529)
( H B ) 22 =

114 331 23 620

= 266 Brinell
341

The pinion contact strength is found using the relation from Prob. 15-7:
(sac ) P = (sac ) G m 0G.0602 C H = 114 331(1) 0.0602 (1) = 114 331 psi
114 331 23 600
= 266 Brinell
341
Core Case
Pinion
180
266
Gear
180
266
Realization of hardnesses
The response of students to this part of the question would be a function of the extent
to which heat-treatment procedures were covered in their materials and manufacturing
( H B ) 12 =

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Chapter 15

391

prerequisites, and how quantitative it was. The most important thing is to have the student think about it.
The instructor can comment in class when students curiosity is heightened. Options
that will surface may include:
Select a through-hardening steel which will meet or exceed core hardness in the hotrolled condition, then heat-treating to gain the additional 86 points of Brinell hardness
by bath-quenching, then tempering, then generating the teeth in the blank.
Flame or induction hardening are possibilities.
The hardness goal for the case is sufficiently modest that carburizing and case hardening may be too costly. In this case the material selection will be different.
The initial step in a nitriding process brings the core hardness to 3338 Rockwell
C-scale (about 300350 Brinell) which is too much.
Emphasize that development procedures are necessary in order to tune the Black Art
to the occasion. Manufacturing personnel know what to do and the direction of adjustments, but how much is obtained by asking the gear (or gear blank). Refer your students
to D. W. Dudley, Gear Handbook, library reference section, for descriptions of heattreating processes.
15-12

Computer programs will vary.

15-13

A design program would ask the user to make the a priori decisions, as indicated in
Sec. 15-5, p. 786, SMED8. The decision set can be organized as follows:
A priori decisions

Function: H, K o , rpm, mG , temp., N L , R

Design factor: n d (S F = n d , S H = n d )
Tooth system: Involute, Straight Teeth, Crowning, n
Straddling: K mb
Tooth count: N P ( NG = m G N P )

Design decisions

Pitch and Face: Pd , F

Quality number: Q v
Pinion hardness: ( H B ) 1 , ( H B ) 3
Gear hardness: ( H B ) 2 , ( H B ) 4

392


n 11

44( HB ) 11 + 2100
48( HB ) 11 + 5980

SF

all
(sat1 ) P (K L ) P
=
=

s11 K T K R

n 21

44( HB ) 21 + 2100
48( HB ) 21 + 5980

(sat1 ) G (K L ) G
=
s21 K T K R

(sat1 ) G =

( HB ) 21

s21 SF K T K R
(K L ) G

( HB ) 11

(sat1 ) P =

Note: SF = n d , S H =

Factor of
safety

New tabulated
strength

Chosen
hardness

Associated
hardness

(sat ) G =

(sat ) G 2100

44
Bhn =
)
5980
(s

at
G

48

s11 SF K T K R
(K L ) P

1/2

n 12

= s12

2

341( HB ) 12 + 23 620
363.6( HB ) 12 + 29 560
(sac1 ) P (C L ) P (C H ) P
=
s12 K T C R

(sac1 ) P =

( HB ) 12

(s
ac ) P 23 620

341
Bhn =
)
29 560
(s

ac
P

363.6

s12 S H K T C R
(C L ) P (C H ) P

W t K o K v Cs C xc
Fd P I

(sac ) P =

c = C p

s22 S H K T C R
(C L ) G (C H ) G

n 22

2

341( HB ) 22 + 23 620
363.6( HB ) 22 + 29 560
(sac1 ) G (C L ) G (C H ) G
=
s22 K T C R

(sac1 ) G =

( HB ) 22

(s
ac ) G 23 620

341
Bhn =
1
)
29 560
(s

ac
G

363.6

(sac ) G =

s22 = s12

Gear Wear

17:42

(sat ) P 2100

44
Bhn =
)
5980
(s

at
P

48

(sat ) P =

W t P Ko Kv Km Ks
st =
= s21
F K x JG

W t P Ko Kv Km Ks
st =
= s11
F K x JP

Pinion Wear

12/05/2006

Tabulated
strength

Load-induced
stress (Allowable
stress)

Gear Bending

Pinion Bending

First gather all of the equations one needs, then arrange them before coding. Find the required hardnesses, express the consequences of the
chosen hardnesses, and allow for revisions as appropriate.

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393

Chapter 15

15-14

N W = 1, NG = 56, Pt = 8 teeth/in, d = 1.5 in, Ho = 1hp, n = 20 , ta = 70 F,

K a = 1.25, n d = 1, Fe = 2 in, A = 850 in2
m G = NG /N W = 56,

(a)

px = /8 = 0.3927 in,

D = NG /Pt = 56/8 = 7.0 in

C = 1.5 + 7 = 8.5 in

Eq. (15-39):

a = px / = 0.3927/ = 0.125 in

Eq. (15-40):

b = 0.3683 px = 0.1446 in

Eq. (15-41):

h t = 0.6866 px = 0.2696 in

Eq. (15-42):

do = 1.5 + 2(0.125) = 1.75 in

Eq. (15-43):

dr = 3 2(0.1446) = 2.711 in

Eq. (15-44):

Dt = 7 + 2(0.125) = 7.25 in

Eq. (15-45):

Dr = 7 2(0.1446) = 6.711 in
c = 0.1446 0.125 = 0.0196 in

Eq. (15-46):


( FW ) max = 2 2(7)0.125 = 2.646 in

Eq. (15-47):

VW = (1.5)(1725/12) = 677.4 ft/min

(7)(1725/56)
= 56.45 ft/min
12


1 0.3927
= 4.764
L = px N W = 0.3927 in, = tan
(1.5)
VG =

Eq. (13-28):

Eq. (15-62):

Pt
8
=
= 8.028
cos
cos 4.764

pn =

= 0.3913 in
Pn

(1.5)(1725)
= 679.8 ft/min
12 cos 4.764


f = 0.103 exp 0.110(679.8) 0.450 + 0.012 = 0.0250

Vs =

(b) Eq. (15-38):

Eq. (15-54):
e=

Pn =

The efficiency is,

cos 20 0.0250 tan 4.764

cos n f tan
=
= 0.7563 Ans.
cos n + f cot
cos 20 + 0.0250 cot 4.764
33 000 n d Ho K a
33 000(1)(1)(1.25)
=
= 966 lbf Ans.
VG e
56.45(0.7563)


cos n sin + f cos
t
= WG
cos n cos f sin


cos 20 sin 4.764 + 0.025 cos 4.764
= 106.4 lbf Ans.
= 966
cos 20 cos 4.764 0.025 sin 4.764

Eq. (15-58): WGt =

t
Eq. (15-57): WW

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Eq. (15-36):

Cs = 1190 477 log 7.0 = 787


Cm = 0.0107 562 + 56(56) + 5145 = 0.767

Eq. (15-37):

Cv = 0.659 exp[0.0011(679.8)] = 0.312

(c) Eq. (15-33):

Eq. (15-38):

(W t ) all = 787(7) 0.8 (2)(0.767)(0.312) = 1787 lbf

Since WGt < (W t ) all , the mesh will survive at least 25 000 h.
Eq. (15-61): W f =

0.025(966)
= 29.5 lbf
0.025 sin 4.764 cos 20 cos 4.764

Eq. (15-63): H f =

29.5(679.8)
= 0.608 hp
33 000

HW =

106.4(677.4)
= 2.18 hp
33 000

HG =

966(56.45)
= 1.65 hp
33 000

The mesh is sufficient

Ans.
Pn = Pt /cos = 8/cos 4.764 = 8.028
pn = /8.028 = 0.3913 in

G =

966
= 39 500 psi
0.3913(0.5)(0.125)

The stress is high. At the rated horsepower,

G =

1
39 500 = 23 940 psi acceptable
1.65

(d) Eq. (15-52): Amin = 43.2(8.5) 1.7 = 1642 in2 < 1700 in2
Eq. (15-49): Hloss = 33 000(1 0.7563)(2.18) = 17 530 ft lbf/min
Assuming a fan exists on the worm shaft,
Eq. (15-50):
Eq. (15-51):

h C R =

1725
+ 0.13 = 0.568 ft lbf/(min in2 F)
3939

ts = 70 +

17 530
= 88.2 F Ans.
0.568(1700)

38.2
36.2
1.47
3
30
854
0.759
0.236
492
2430
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
7290
16.71

38.2
36.2
1.87
3
30
607
0.759
0.236
492
2430
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
5103
16.71

HW
HG
Hf
NW
NG
KW
Cs
Cm
Cv
VG
WGt
t
WW
f
e
( Pt ) G
Pn
C-to-C
ts
L

G
dG

1.75
3.60
1.68
2000

1.75
3.60
2.40
2000

15-16

px
dW
FG
A

15-15

492
2430
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
7247
16.71

492
2430
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
5103
16.71

38.2
36.2
1.97
3
30
80

1.75
3.60
2.40
2000

15-19

563
2120
1038
0.0183
0.951
1.571
1.732
11.6
171
6.0
24.98
4158
19.099

38.0
36.1
1.85
3
30
50

1.75
4.10
2.25
2000

15-20

492
2524
1284
0.034
0.913
1.795
1.979
10.156
179.6
5.25
24.9
5301
16.7

1.75
3.60
2.4
2500
FAN
41.2
37.7
3.59
3
30
115

15-21

492
2524
1284
0.034
0.913
1.795
1.979
10.156
179.6
5.25
24.9
5301
16.71

1.75
3.60
2.4
2600
FAN
41.2
37.7
3.59
3
30
185

15-22

Page 395

1000
0.759
0.236
492
2430
1189
0.0193
0.948
1.795
1.979
10.156
177
5.25
24.9
8565
16.71

38.2
36.2
1.97
3
30
125

1.75
3.60
1.69
2000

15-18

17:42

38.2
36.2
1.97
3
30

1.75
3.60
1.43
2000

15-17

12/05/2006

#1
#2
#3
#4

Parameters
Selected

15-15 to 15-22
Problem statement values of 25 hp, 1125 rev/min, m G = 10, K a = 1.25, n d = 1.1, n = 20, ta = 70F are not referenced in the table.

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